U.S. patent number 7,614,150 [Application Number 10/604,760] was granted by the patent office on 2009-11-10 for method for manufacturing a stator or rotor component.
This patent grant is currently assigned to Volvo Aero Corporation. Invention is credited to Jan Lundgren.
United States Patent |
7,614,150 |
Lundgren |
November 10, 2009 |
Method for manufacturing a stator or rotor component
Abstract
Method and arrangement for providing a stator or rotor component
that is intended during operation to conduct a gas flow. A first
wall part (14, 15) is placed with its one edge bearing against the
flat side of a second wall part (9, 10), extending in the radial
direction of the component, in such a way that the first wall part
extends in the circumferential direction of the component. The edge
of the first wall part is then laser-welded to the second wall part
from an, in the circumferential direction, opposite side of the
second wall part in relation to the first wall part in such a way
that the joined-together portions of the wall parts form a T-shaped
joint.
Inventors: |
Lundgren; Jan (Grundsund,
SE) |
Assignee: |
Volvo Aero Corporation
(Trollhattan, SE)
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Family
ID: |
32396901 |
Appl.
No.: |
10/604,760 |
Filed: |
August 14, 2003 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20040103533 A1 |
Jun 3, 2004 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60402946 |
Aug 14, 2002 |
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Current U.S.
Class: |
29/889.21;
29/596 |
Current CPC
Class: |
B23K
26/24 (20130101); F01D 9/04 (20130101); B23K
26/037 (20151001); F05D 2230/23 (20130101); B23K
2103/05 (20180801); Y10T 29/49009 (20150115); Y10T
29/49321 (20150115); F05D 2230/13 (20130101) |
Current International
Class: |
H02K
15/00 (20060101); B21K 25/00 (20060101) |
Field of
Search: |
;29/889.21,889.22,889.2,889,889.23,890.01,596 ;310/259,164 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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3942051 |
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Dec 1989 |
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DE |
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995673 |
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Sep 1999 |
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EP |
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Primary Examiner: Hong; John C
Attorney, Agent or Firm: Novak Druce + Quigg LLP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional
Application No. 60/402,946 filed Aug. 14, 2002. Said application is
expressly incorporated herein by reference in its entirety.
Claims
The invention claimed is:
1. A method for manufacturing a generally ring-shaped stator or
rotor component which is intended during operation to conduct a gas
flow, comprising: constructing a portion of said stator or rotor
component by steps including 1) providing a curved first wall part
having one edge bearing against a flat side of a second wall part
that extends in a direction corresponding to an eventual radial
direction of the component in such a way that the first wall part
extends and curves in a direction corresponding to an eventual
circumferential direction of the component and also extends in a
direction corresponding to an eventual axial direction of the
component; and 2) laser-welding the edge of the first wall part to
the second wall part from an, in the circumferential direction,
opposite side of the second wall part in relation to the first wall
part in such a way that the joined-together portions of the wall
parts form a T-shaped joint; wherein a sufficient number of stator
or rotor component portions are so constructed and are mutually
arranged so as to form the stator or rotor component, with the
curved first wall parts of the stator or rotor components defining
an axially extending, substantially annular flow-guiding surface
that delimits a gas duct in said eventual radial direction.
2. The method as recited in claim 1, wherein the first wall part of
said stator or rotor component portion abuts the flat side of the
second wall part in generally perpendicular fashion.
3. The method as recited in claim 1, wherein the second wall part
of said stator or rotor component portion is arranged such that it
also extends in the direction corresponding to the eventual axial
direction of the component.
4. The method as recited in claim 1, wherein the second wall part,
extending in the direction corresponding to the eventual radial
direction of the stator or rotor component, is arranged so as to
circumferentially limit said gas duct in the direction
corresponding to the eventual circumferential direction of the
component.
5. The method as recited in claim 1, wherein the second wall part
is arranged such that it has an essentially radial widening for
guidance of the gas flow and/or transmission of load during
operation of the component.
6. The method as recited in claim 1, wherein the first wall part is
placed with a second edge, which is opposite to the first-named
edge, bearing against the flat side of a further second wall part,
which is arranged at a distance in the circumferential direction
from the first-named second wall part, and is connected
thereto.
7. The method as recited in claim 6, wherein the second edge of the
first wall part is also laser-welded to this further second wall
part from an, in the circumferential direction, opposite side of
the second wall part in relation to the first wall part in such a
way that the joined-together portions of the wall parts form a
T-shaped joint.
8. The method as recited in claim 6, wherein the two second wall
parts which are spaced apart in the circumferential direction
constitute at least part of two different blades or stays for
guidance of a gas flow and/or transmission of load.
9. The method as recited in claim 6, wherein the two second wall
parts are formed by a single, substantially U-shaped element.
10. The method as recited in claim 9, wherein the first and second
wall part are arranged between an, in the radial direction, inner
and outer ring element and the U-shaped element, prior to the
laser-welding of the wall parts, is arranged between the inner ring
element and the outer ring element.
11. The method as recited in claim 1, wherein the first and second
wall part are arranged between an, in the radial direction, inner
and outer ring element.
12. The method as recited in claim 11, wherein the second wall part
is connected to at least one of the ring elements by laser-welding
from an, in the radial direction, opposite side of the ring element
in relation to the second wall part in such a way that the
joined-together portions form a T-shaped joint.
13. The method as recited in claim 1, wherein the stator or rotor
component is intended for a gas turbine.
14. The method as recited in claim 1, wherein the stator or rotor
component is intended for a jet engine.
Description
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing a
stator or rotor component that is intended during operation to
conduct a gas flow. The stator or rotor component can, for example,
be used in a gas turbine and especially in a jet engine.
As used herein, jet engine is meant to include various types of
engines that admit air at relatively low velocity, heat it by
combustion and shoot it out at a much higher velocity. Included
within the term jet engine are, for example, turbojet engines and
turbo-fan engines.
A component of this kind, comprising (including, but not limited
to) an outer and an inner ring with wall parts configured between
the rings, can be arranged with a view to primarily being
force-transmitting in the radial and axial direction. The wall
parts can, for example, form hollow blades, which are usually
shaped such that they offer as little air resistance as possible.
The component can, for example, be arranged in a rear or front
stand, or in an intermediate housing in a jet engine. The blades
are often referred to in such a case as stays or "struts." Struts
can, however, also be formed by other types of parts than hollow
blades.
2. Background Art
Wall parts in the form of hollow blades are known that are arranged
at a distance apart in the circumferential direction of the
carrying component between an inner and an outer ring. The hollow
blades are joined together with the rings by welding. Each of the
rings is made in this case firstly with portions of the same
cross-dimensional shape and size as the blades, protruding in the
radial direction. Such protruding portions are often referred to as
"stubs." Each of the blades are then welded to a protruding portion
of this kind by means of a butt joint. The radially protruding
portions are usually mill-cut from a ring. This is a time-consuming
and costly operation.
SUMMARY OF INVENTION
One objective of the present invention is to achieve a method for
manufacturing a stator or rotor component that creates, or
establishes, preconditions for manufacture that is simplified and
hence time-effective and cost-effective in relation to previous
methods. Further, a high-strength component with long working life
will be produced with the method. This objective is achieved by
virtue of the fact that a first wall part is placed with its one
edge bearing against the flat side of a second wall part, extending
in the intended radial direction of the component, in such a way
that the first wall part extends in the intended circumferential
direction of the component. The edge of the first wall part is then
laser-welded to the second wall part from an, in the
circumferential direction, opposite side of the second wall part in
relation to the first wall part in such a way that the
joined-together portions of the wall parts form a T-shaped
joint.
By the edge of the wall part, the elongated surface that delimits
the side faces, or flat sides, of the wall part is meant. Given an
appropriate choice of material parameters and welding parameters, a
T-shaped joint with rounded corners, or at least a relatively
smooth transition can be obtained between the wall parts. This
produces a structurally strong construction and hence an extended
working life. Alternatively, a construction with thinner wall
thicknesses and hence reduced weight can be obtained.
According to a preferred embodiment of the invention, the first
wall part is placed with a second edge, which is opposite to the
first-named edge, bearing against the flat side of a further second
wall part, which is arranged at a distance in the circumferential
direction from the first-named second wall part and is connected
thereto. Further, the two wall parts that are spaced apart in the
circumferential direction are constituted by two different blades
or stays for guidance of a gas flow and/or transmission of load.
The first wall part thus serves to limit a gas duct in the radial
direction between the two blades or stays.
According to a refinement of the previous embodiment, the two
second wall parts are formed by a single, substantially U-shaped
element. The two wall parts are constituted by a portion of the
particular leg of the U.
Further preferred embodiments of, and advantages with, the
invention can be ascertained from the claims, drawings, and
following description.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be described in greater detail below, with
reference to the embodiments shown in the appended drawings, in
which:
FIG. 1 shows a basic diagram of the connection between two wall
parts forming part of the stator or rotor component according to
the teachings of the present invention;
FIG. 2 shows an enlarged sectional view of a weld joint in the
component shown in FIG. 1;
FIG. 3 shows a first preferred embodiment of a component in a cut
projection;
FIG. 4 shows a schematic projection of the component shown in FIG.
3; and
FIG. 5 shows a schematic projection of the component according to a
second preferred embodiment.
DETAILED DESCRIPTION
FIG. 1 shows a basic diagram of a connection of a first and second
wall part 1, 2 forming part of a stator component. The axial
direction, radial direction and circumferential direction of the
component are marked in the Fig. with the arrows A, B, C.
The second wall part 2 is arranged firstly so that it extends
essentially in the intended radial and axial direction A, B of the
component. The first wall part 1 is placed with its one edge 3
bearing against the flat side 4 of the second wall part in such a
way that the first wall part extends essentially in the
circumferential direction C of the component and in its axial
direction A. By the edge 3 of the first wall part 1 is thus meant
the surface connecting its side faces, or flat sides.
The edge 3 of the first wall part 1 is then laser-welded to the
second wall part 2 from an, in the circumferential direction,
opposite side of the second wall part 2 in relation to the first
wall part 1 in such a way that the joined-together portions of the
wall parts form a T-shaped joint 5 (see FIG. 2). The laser-welding
is illustrated with the arrow D in FIG. 1.
By T-joint 5 it is meant, more precisely, that a portion of the
second wall part 2 forms the top part of the T and a portion of
FIGS. 3 and 4 show a first preferred embodiment of the component.
Each of a plurality of essentially U-shaped elements 6, 17, 23 are
connected to an inner ring element 7 and are placed adjacent to one
another in the circumferential direction of the component. The one
side member of the U-shaped element 6 forms a second wall part 9
and its other side member forms a further second wall part 10. The
base of the U-shaped element 6 is connected to the inner ring
element 7 by a rib 11, which extends in the intended axial
direction of the component. The ends 12, 13 of the two side members
are later connected to an outer ring element 8 (see FIG. 4). Each
of the two second wall parts 9, 10 thus extend essentially in the
radial and axial direction of the component. The U-shaped element
can be made, for example, by curving or bending a plate or a sheet
into the desired shape.
Further, two first wall parts 14, 15 are placed such that they
extend in the circumferential direction of the component and at
various distances apart in the radial direction between the two
second wall parts 9, 10. More precisely, the two first wall parts
14, 15 are placed such that they bear with their end edges against
the flat side of the second wall parts 9, 10. The end edges of the
first wall parts 14, 15 are then laser-welded to the second wall
parts 9, 10 from an, in the circumferential direction, opposite
side of the second wall part 9, 10 in relation to the first wall
part 14, 15. The laser-welding is realized in such a way that the
joined-together portions of the wall parts 9, 10, 14, 15 form a
T-shaped joint (see FIG. 2).
The first wall part 15 that limits a gas duct 20 inwardly in the
radial direction forms an intermediate portion of a plate-shaped
member. This plate-shaped member has a shape corresponding to the
space between the second radial wall parts 9, 10 (see FIG. 3). The
plate-shaped member has a U-shaped cross section and is
constituted, for example, by a bent, or folded sheet. The side or
plate portions 18 of the plate-shaped member have a shape and size
corresponding to the space between the second wall parts 9, 10. The
side portions of the plate-shaped member are expediently connected
to the second wall parts 9, 10 by laser-welding.
The first wall part 14 that limits the gas duct 20 outwardly in the
radial direction forms an intermediate portion of a further
plate-shaped member. This plate-shaped member has a shape
corresponding to the space between the second radial wall parts 9,
10 (see FIG. 3). The plate-shaped member also has a U-shaped cross
section and is constituted, for example, by a bent, or folded
sheet, or by a tube or other profile. The side or plate portions 19
of the plate-shaped member have a shape and size corresponding to
the space between the second wall parts 9, 10. The side portions of
the plate-shaped member, too, are connected to the second wall
parts 9, 10 expediently by laser-welding.
Each of the side members of the U-shaped element 6 are connected to
a side member 16 of an, in the circumferential direction, adjoining
U-shaped element 17 in such a way that gas cannot flow between the
side members (see FIG. 4). The mutually connected wall parts 9, 16
together form means for guidance of a gas flow and/or transmission
of load in the radial direction during operation of the
component.
The adjoining wall parts 9, 16 are connected in FIG. 4 by a front
and a rear cover wall 24, which thus enclose a space between the
wall parts. These cover walls 24 are aerodynamically configured and
have, in this case, a pointed shape so as to offer as little flow
resistance as possible. This connection can be produced, for
example, by welding. The two connected side members together form a
blade, vane, stay or strut for guidance of a gas flow and/or
transmission of load. In other words, the two wall parts of the
U-shaped element that are spaced apart in the circumferential
direction form two different blades or stays for guidance of a gas
flow and/or transmission of load.
FIG. 4 shows a schematic projection of a stator or rotor component
21 constructed according to the technique described above and
illustrated in FIG. 3. The component 21 has an essentially circular
cross-sectional shape and the ducts 20 for conduction of the gas
flow extend in the axial direction between the inner ring, formed
by the ring elements 7, and the outer ring 8.
FIG. 5 illustrates a second embodiment of the stator component 23.
A basic difference relative to the first embodiment is that the two
spaced apart second wall parts 109, 110 do not form part of a
U-shaped element, but constitute separate units. All the wall parts
109, 110 in the component are first connected to a continuous inner
ring 107. The first wall parts 114, 115 are connected to the second
wall parts 109, 110 in the same manner as described above for the
first embodiment. An outer ring 108 is then arranged around the
wall parts 109, 110 and connected thereto.
The materials which are used for the first and second wall parts 1,
2, 9, 10, 14, 15, 109, 110, 114 are constituted by weldable
materials such as stainless steel, for example of the type 347 or
A286. Alternatively, nickel-based alloys, such as, for example,
INCO600, INCO625,
In the laser-welding, a Nd:YAG-laser is preferably used, but also
other types of welding arrangements, for example a CO.sub.2-laser,
can be used according to the invention. By precise coordination of
the welding method, materials choice and wall part dimensions, the
T-shape in respect of a particular joint and a relatively gently
rounded shape 22 of the inner angle between the second wall part
and the first wall part are obtained with the laser-welding (see
FIG. 2). The welding is expediently realized by means of a
continuous weld. The rounded shape of the weld joints produces a
high-strength construction and hence long working life for the
component. This type of joining-together creates preconditions for
a complete melting of the weld joint and fine transitions between
the parts.
In order for the weld joint to end up in exactly the right
position, a previously known joint-following technique can be
used.
The wall part has the shape of a plate. By plate-shape, it is meant
that the wall parts have two parallel side faces at a relatively
short distance apart.
By use of the term ring element, a continuously annular member, a
substantially annular member interrupted in the circumferential
direction, or a part that, together with other like parts, is
intended to form an annular member is meant. When a plurality of
such ring elements are joined together in the circumferential
direction, a ring is formed. Ring is used to mean a
circumferential, band-shaped, preferably circular part that spreads
like a plate in the axial direction.
Should the wall parts have the purpose of being load-transmitting
or load-bearing in the radial direction, that is to say when they
form so-called struts or stays, an airfoil shape is not always
required, nor the shape of hollow blades, but rather the
plate-shape can suffice. A plurality of different configurations
are, however, possible.
Should the second wall parts have the purpose of guiding a gas flow
during operation of the component, the mutually connected second
wall parts form the shape of a blade, for example, having an
airfoil shape in cross section. Such a blade shape is utilized when
the component is used in specific stator applications.
The first wall part is not limited to just rounded or curved
cross-sectional shape, but rather, for example, a square
cross-sectional shape; that is to say, made up of essentially
straight portions of different direction or orientations are also
included.
By the expression that the wall parts extend in a certain direction
or orientation with respect to the component is meant that at least
one component of the extent of the wall part lies in this
direction. Preferably, the wall part extends substantially in this
direction. In other words, the wall part in question extends in a
plane parallel with the direction.
The stator component can, for example, form an inlet part, an
intermediate housing, or a turbine-exhaust housing; by exhaust
housing, a concluding housing part, or part thereof for a gas
turbine is meant. Its primary function in this case is to act as a
bearing fastening, for the transmission of loads, and to provide a
duct for gases.
By the expression that a wall part is placed such that it extends
in the intended radial direction of the component, it is meant both
that the wall part is placed directly in a structure in the radial
direction of the component and that the wall part is first mounted
in a section and that a plurality of such sections are then
mutually connected in the circumferential direction so that the
wall part ends up in the radial direction. The equivalent applies
to when a wall part is placed so that it extends in the intended
axial direction of the component and in its circumferential
direction.
The invention will not be deemed limited to the illustrative
embodiments described above, but a host of further variants and
modifications are conceivable within the scope of the subsequent
patent claims.
The connection of a wall part extending in the radial direction to
another wall part extending in the radial direction can further be
affected differently than arranging a cover plate therebetween. For
example, the wall parts can be arranged relatively close together
and connected by the application of material, for example, by
welding. Further, the cover plates can be fixed in a number of
different of ways, such as riveting and gluing.
It is further conceivable for a plurality of separate sections to
be made, each comprising a first and a second wall part, and which
sections each in cross section form a sector of a circle. The
sections are then connected in the intended circumferential
direction of the component to form the stator or rotor component.
In other words, in the construction of the section, the second wall
part is arranged in the intended radial direction of the component
and the first wall part in the intended circumferential direction
of the component. When a plurality of such sections are put
together, the second wall part thus ends up such that it extends in
the radial direction of the component and the first wall part ends
up such that it extends in the circumferential direction of the
component.
* * * * *